Product delivery and monitoring system

• US 8,833,605 B2
• Filed: 07/18/2011
• Issued: 09/16/2014
• Est. Priority Date: 07/20/2010
• Status: Active Grant

• Current Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Original Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Inventors: Mehus, Richard J., Grapes, Robert D., Unwin, James
• Primary Examiner(s): Shaver, Kevin P
• Assistant Examiner(s): Buechner, Patrick M
• Application Number:
  US13/184,801
• Publication Number:
  US 20120018448A1
• Time in Patent Office: 1,156 Days
• Field of Search: 222/63, 222/135, 222/1, 134/56.D, 134/113
• US Class Current: 222/1
• CPC Class Codes: A47L 15/0055 Metering or indication of used products, e.g. type or quantity of detergent, rinse aid or salt; for measuring or controlling the product concentration
• CPC Class Codes: A47L 15/4418 in the form of liquids A47L15/4409, A47L15/4436, A47L15/4445 take precedence
• CPC Class Codes: A47L 2401/023 Quantity or concentration of the consumable product
• CPC Class Codes: A47L 2501/26 Indication or alarm to the controlling device or to the user
• CPC Class Codes: B67D 7/0266 by gas acting directly on the liquid
• CPC Class Codes: F04B 2201/06062 of the outlet valve
• CPC Class Codes: F04B 2203/10 of linear elastic fluid motors
• CPC Class Codes: F04B 2207/70 Warnings
• CPC Class Codes: F04B 43/0081 systems, control, safety measures
• CPC Class Codes: F04B 43/067 the fluid being actuated directly by a piston
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 49/106 Responsive to pumped volume

Abstract

A product delivery and monitoring system is provided. The system includes at least one air pump, an air pump sensor for each air pump, at least one diaphragm pump, a diaphragm pump sensor for each diaphragm pump, a controller and an indication system. Each air pump sensor is configured and arranged to monitor the operation of the air pump. The at least one diaphragm pump is configured and arranged to deliver a product in response to the operation of an associated air pump. Each diaphragm pump sensor is configured and arranged to monitor the delivery of the product by the diaphragm pump. The controller is in communication with each air pump sensor and each diaphragm pump sensor. The controller is configured to generate at least one control signal based on a comparison of communications from an air pump sensor and an associated diaphragm sensor. The controller is configured to manipulate the indication system with the at least one control signal.

Claims

1. A product delivery and monitoring system comprising:

at least one first pump associated with a product;

a first sensor for each first pump, each first pump sensor configured and arranged to monitor the operation of the at least one first pump;

at least one second pump operated by the at least one first pump to deliver the product;

a second pump sensor for each second pump, each second pump sensor configured and arranged to monitor the delivery of the product by the at least one second pump;

a controller in communication with each first pump sensor and each second pump sensor, the controller configured to generate at least one signal based at least in part on comparisons between communications between the controller and a first pump sensor and the controller and an associated second pump sensor; and

wherein the controller is further configured to determine at least one of proof of delivery, out of product, dosing amount and low product alert based at least in part on the comparisons between the communications between the controller and the first pump sensor and the controller and the second pump sensor.

2. The product and delivery system of claim 1, wherein the at least one first pump is at least one air pump and the at least one second pump is at least one diaphragm pump.

3. The product and delivery system of claim 1, further comprising:

an indication system in communication with the controller, the controller configured to manipulate the indication system based on the comparison of the signals.

4. A product delivery and monitoring system, the system comprising:

at least one air pump associated with a product;

an air pump sensor for each air pump, each air pump sensor configured and arranged to monitor the operation of the air pump;

at least one diaphragm pump operated by the at least one air pump to deliver the product;

a diaphragm pump sensor for each diaphragm pump, each diaphragm pump sensor configured and arranged to monitor the delivery of the product by the diaphragm pump;

a controller in communication with each air pump sensor and each diaphragm pump sensor, the controller configured to generate at least one control signal based on a comparison of communications from an air pump sensor and an associated diaphragm sensor;

wherein the controller is further configured to determine at least one of proof of delivery, out of product, dosing amount and low product alert based at least in part on the comparisons between the communications between the controller and the air pump sensor and the controller and the diaphragm pump sensor; and

an indication system in communication with the controller, the controller configured to manipulate the indication system with the at least one control signal.

5. The system of claim 4, wherein the diaphragm pump further comprises:

a valve configured to open to allow product to pass when pressure is applied to the valve by the product; and

a magnet coupled to the valve, the magnet producing a magnetic field, the diaphragm sensor including a hall-effect sensor positioned to detect changes in the strength of the magnetic field as the valve is opened to allow product to pass.

6. The system of claim 4, further comprising:

an input to provide information to the controller.

7. The system of claim 4, further comprising:

a timer system in communication with the controller to set out a timing of operational functions of the system.

8. The system of claim 4, wherein the indication system includes at least one of a light activated by the controller.

9. The system of claim 4, further comprising:

the at least one air pump including a piston received in a chamber;

a first air magnet coupled to the piston of the at least one air pump;

the pump sensor including an air hall-effect sensor positioned and configured to detect a magnetic field generated by the first air magnet;

the at least one diaphragm pump including a cartridge check valve with a check valve; and

a second diaphragm magnet coupled to the check valve of the cartridge check valve;

the diaphragm sensor including a diaphragm hall-effect sensor positioned and configured to detect a magnetic field generated by the second diaphragm magnet.

10. The system of claim 9, wherein the controller is further configured to determine the operation of the air pump by monitoring changes in the magnetic field detected by the pump sensor and the delivery of product by diaphragm pump by monitoring changes in the magnetic field detected by the diaphragm sensor.

11. A method of providing a product delivery and monitoring system, the method comprising:

monitoring movement of a piston of at least one air pump that is associated with a product;

monitoring operation of at least one diaphragm pump that delivers the product, each diaphragm pump being configured and arranged to activate in response to movement of a piston of an associated air pump;

comparing activity from the at least one diaphragm pump in response to the activation of an associated air pump;

based at least in part on the comparison, generating a select control signal; and

activating an out of product indicator when an one-to-one correlation is not found during the comparison.

12. The method of claim 11, wherein monitoring movement of the piston of the at least one air pump further comprises:

monitoring for changes in a magnetic field produced by a magnet coupled to the piston of the at least one air pump with a hall-effect sensor that is in communication with a controller.

13. The method of claim 11, wherein monitoring the operation of the at least one diaphragm pump further comprises:

monitoring for changes in a magnetic field produced by a magnet in a check valve of the diaphragm pump with a hall-effect sensor that is in communication with the controller.

14. The method of claim 11, further comprising:

once a one-to-one correlation is found during the comparison, counting a number of diaphragm strokes;

when a select number of diaphragm strokes have been counted, turning off the associated air pump; and

activating a product dosage delivered indicator.

15. The method of claim 14, further comprising:

counting a number of dosages delivered by the at least one diaphragm pump; and

when the number of dosages are greater than a select number, activating a low product indicator.

16. The method of claim 14, further comprising:

adjusting the select number of diaphragm strokes that make up a dosage.

17. A method of providing a product delivery and monitoring system, the method comprising:

monitoring movement of a piston of at least one air pump that is associated with a product;

monitoring operation of at least one diaphragm pump that delivers the product, each diaphragm pump being configured and arranged to activate in response to movement of a piston of an associated air pump;

comparing activity from the at least one diaphragm pump in response to the activation of an associated air pump; and

based at least in part on the comparison, generating a select control signal; and

activating at least one of an out of product indicator, proof of delivered product indicator and a low product indicator with the select control signal.